Differential press tool

ABSTRACT

Embodiments of the invention generally provide a fixture for assembling an optical component. The fixture includes a substantially rigid base member having an upper surface and a lower surface with a base aperture connecting the two surfaces and a component mounting plate positioned on the upper surface and having an aperture formed therein corresponding to the base aperture. The fixture further includes at least one pivotally mounted component disengagement member positioned on the upper surface and being configured to disengage a component from the mounting plate and a component securing member slidably positioned on the upper surface and being configured to secure a component to the mounting plate. Additionally, a differential press screw assembly is positioned on the lower surface, wherein the differential press screw assembly is configured to press a lens into a component mounted on the component mounting plate via extension of a press nut through the base aperture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. provisional patent applicationser. No. 60/422,279 filed Oct. 30, 2002 which is herein incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention generally relate to and apparatus andmethod for assembling optical components. More particularly, embodimentsof the invention relate to an apparatus and method for assembling anoptical source or an optical lens into an optical housing in a power-onstate.

2. Description of the Related Art

Assembly of optical components is generally accomplished via simplemechanical operations that may be automated. Although the automationprovides for increased throughput and accuracy in the assembly process,the components are nevertheless generally tested after the assemblyprocess to determine if the component is within tolerances. Therefore,optical component assembly processes are generally a two step process,wherein the first step is the assembly and the second step, which isconducted in a separate apparatus, is generally an inspection step.

Inasmuch as multiple steps require more resources to manufacturecomponents, is desirable to eliminate the requirement to assemble thecomponent and measure the component in separate apparatuses.

SUMMARY OF THE INVENTION

Embodiments of the invention may generally provide an apparatusconfigured to assemble optical devices, and further, during the assemblyprocess (real time), the apparatus measures input/output signals of theoptical devices to correct optical offsets that may be inherent in themanufacturing process. The apparatus generally includes an outer frameand an inner frame, wherein the inner frame is vibrationally isolatedfrom the outer frame, i.e., the inner frame is isolated from noiseassociated with or encountered by the outer frame. The inner framegenerally supports a work plate configured to receive one of a pluralityof component assembly fixtures thereon, wherein the individual fixturesare each configured for a particular optical component assembly process.The work plate also operates to position the assembly componentsrelative to an optical measurement system, which is used to determineoffset of the components prior to completion of the manufacturingprocess. The optical measurement system includes a camera adapted toreceive an optical signal from an assembled optical device positioned inthe assembly fixture. The camera receives light from a split light pathhaving a specialized backlight system adapted to enhance the appearanceof the optical signal. The output of the camera is fed into a dataprocessing and display system configured to display the output to theuser. The output may generally be presented to the user via a display,wherein the display may illustrate the focus of the output, intensity ofthe output, positioning of the output, and the offset of the output.Using the display, the user may adjust the offset of the componentbefore assembly is completed, as well as measure and record variousother optical parameters of the component that may be relevant to futurecomponent operation, installation, manufacturing, or other processes.

Embodiments of the invention may further provide an apparatus and methodto assemble optical components and measure the resultant performance ofthe components during assembly and adjust the assembly process insitu toprovide an improved optical component. The apparatus and method provideimproved 3D imaging for positional information relative to the outputoptical signal of the component. The optical measurement system isvibrationally separated from a work plate to minimize installationerrors. The apparatus is able to measure a plurality of input and outputsignals to determine the optical device performance during assembly.Position based on optical measurement system focus.

Embodiments of the invention may further provide an apparatus and methodfor measuring the optical offset of an optical component with a Z-Cameraaxis measurement device. The method generally includes loading acomponent shell into a fixture mounted on the measurement apparatus andthen inserting an optical source into the component shell. The opticaloutput of the component is then observed by a camera positioned belowthe component. The camera transmits the image of the optical signal to aprocessing device, i.e., a PC, that displays the position/offset of thedevice to the user. In response to the displayed offset, the user mayadjust physical parameters of the component in order to correct for theoffset prior to final assembly of the component. The correction may beautomated in that the system controller may operate to control a processconfigured to automatically adjust the physical parameters of thecomponent to correct for the offset.

Embodiments of the invention may further provide an automated componentassembly fixture and method configured to press an optical assembly intoa housing/body when used in conjunction with an optical componentinstallation and measurement apparatus. The automated apparatus/methodof the invention generally includes relieving backlash in the assemblysystem by making a movement in the direction of the assembly, checkingfor a signal, adjust the x and y coordinates to obtain the signal in themeasurement plane, determine the quadrant of the signal, adjust the zposition and re-verify the image x and y plane, scan in z to determinethe focus, subtract an empirical number from the z distance and drive tothat distance, take a fine z measurement, calculate the appropriate zdistance, drive to the calculated z distance, and release the assembledpart. This process essentially guarantees a 100% part assembly and focuswithout generating any throwaways as a result of overshoot.

Embodiments of the invention may further provide a component assemblyfixture configured to press an optical assembly into a housing/body whenused in conjunction with an optical component assembly and measuringapparatus. The fixture is based upon a top press-type operation, whereinthe optical assembly is pressed into the housing from the backside(electrical contact side) of the optical assembly. The top pressconfiguration provides for high pressure assembly with great accuracy,and therefore, the focus of the optical assembly may be set withoutovershoot, which conventionally results in rendering the componentunusable. Additionally, the top press provides easy insertion andremoval of components. The physical structure generally includes twoslide pins, that capture a pivot point so the pivot point and distallyextending a work bridge may press the optical assembly into thebody/mount. Top press allows for high accuracy press assembly, increasedthroughput, reduced/eliminated throwaways, and easy access for insertionand removal of components.

Embodiments of the invention may further provide a component assemblyfixture configured to press an optical assembly into a housing/body whenused in conjunction with an optical component assembly and measurementapparatus. The fixture is based upon a differential press screw that hastwo opposing thread speeds. Therefore, one side of the differentialpress screw actuates the housing in a positive z direction, while thesecond side of the differential press screw actuates the opticalassembly in a negative z direction. This actuation causes the opticalassembly to be pressed into the housing with great precision using veryfine movements at very high pressure with large circumferential movementof the actuator itself. Thus, the focus of the optical assembly may beset without risking overshoot, which conventionally results in renderingthe component unusable. Additionally, the present invention provides asubstantial improvement in throughput, about 5 times conventionalassembly speeds. The differential screw allows for precise pressing atvery high pressures, which allows for pressing an optical source into ahousing in a one shot-type method without overshooting the focus andrendering the part a throwaway—also without requiring more than onemeasuring step, as with conventional assembly apparatuses.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 illustrates a perspective view of an embodiment of the invention.

FIG. 2 illustrates a partial exploded view of an embodiment of theinvention.

FIG. 3 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention.

FIG. 4 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention having a component therein.

FIG. 5 illustrates a side perspective view of an exemplary cam operatedlaser press assembly fixture of the invention.

FIG. 6 illustrates a side perspective view of an exemplary automated camoperated laser press assembly fixture of the invention.

FIG. 7 illustrates an exemplary fixture of the invention that utilizes adifferential press screw assembly.

FIG. 8 illustrates a sectional view of the differential press screwassembly illustrated in FIG. 7.

FIG. 8 a illustrates a flow diagram of an exemplary method of theinvention.

FIG. 9 illustrates a graphical view of the optical offset measurementprocess.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a perspective view of an embodiment of the invention.The optical component assembly apparatus 100 generally includes asubstantially rigid base member 101 that supports an inner frame member102. Inner frame member 102 is generally separated from the rigid basemember 101 via a plurality of cushioning devices 104. The cushioningdevices 104, which may be air isolators, for example, are generallyconfigured to isolate the components attached to inner frame member 102from any ambient ground noise. The upper portion of inner frame member102 generally includes an optical component press and measuring assembly105. Further, the substantially rigid base member 101 may also supportan outer frame member 103, which may include storage space for themechanical and electronic devices needed to operate the opticalcomponent assembly apparatus 100, while also providing an upper workingsurface for the operators of the apparatus.

More particularly, inner frame member 102 is generally secured to rigidbase member 101 via a plurality of airbags actuators 104. Further, asillustrated in FIG. 1, inner frame member 102 generally includes aplurality of legs radially extending therefrom, which generally attachto the rigid base member 101 via airbags 104. The radial extension ofthe plurality of legs from inner frame member 102 provides for a wideand stable base for the operational components of optical componentassembly apparatus 100, which as will be described further herein,generally attach to the upper portion inner frame member 102.Furthermore, since it is desirable to isolate the working components ofthe assembly apparatus 100 from ambient noise sources, in addition toinner frame member 102 being isolated from rigid base member 101 viaairbags 104, the outer frame member 103 is also isolated from innerframe member 102. More particularly, although outer frame member 103 mayinclude several components of the optical component assembly apparatus100, outer frame member 103 is generally not rigidly secured or attachedto inner frame member 102, and therefore, any actuation of the outerframe member 103 will not affect the component assembly and or measuringprocess taking place within the operational components of apparatus 100that are secured to the upper portion of inner frame member 102.

FIG. 2 illustrates a partial exploded view of an embodiment of theinvention, and more particularly, FIG. 2 illustrates the opticalcomponent assembly apparatus 100 of the invention, wherein the opticalcomponent press and measuring assembly 105 is removed from inner framemember for better illustration. The optical component press andmeasuring assembly 105 is generally secured to an upper portion of innerframe member 102 via a second frame member 201. Second frame member 201generally supports a fixture support 202 on an upper portion thereof. Assuch, the second frame member 201 and fixture support member 200 aregenerally rigidly attached to inner frame member 102. Second framemember 201 also is slidably engaged with a component press and measuringassembly 215 via a Z slide 210. Z slide 210 generally operates to allowthe component press and measuring assembly 215 to move in a Z directionwith respect to the inner frame member 102, wherein the Z direction isgenerally defined as vertically with respect to the substantially rigidbase member 101. However, Z slide 210 is generally configured to presentmotion of the component press and measuring assembly 215 in anydirection other than the Z direction. Additionally, inasmuch asisolation of the component press and measuring assembly 215 is animportant element of the present invention, Z slide 210 may furtherinclude a pneumatic neutralizer 209 attached thereto, whereinneutralizer 209 is generally configured to apply an upward force to thecomponent press and measuring assembly 215 sufficient to neutralize thegravitational force being exerted thereon.

The remaining components of the press and measuring assembly 215 aregenerally supported by a pair of upstanding frame members 203, whereinthe upstanding frame member 203 are generally attached to a surface ofthe Z slide 210. Therefore, when slide 210 is actuated by the manualactuator 211, which generally operates to move slide 210 in an upward ordownward motion, the remaining components of the press and measurementassembly 215 will also move upward or downward, as they are rigidlyattached to slide 210 via frame members 203. However, it is to be notedthat slide 210 moves relative to frame member 201 and 202, andtherefore, movement of slide 210 causes the press and measuringapparatus 215 to move relative to the remaining components of theinvention. Generally speaking, the remaining components generallyinclude an adjustable table 204 and an optical measuring device 207. Theadjustable table 204 generally attaches to the upper portion of framemembers 203, and is configured to linearly move in both X and Ydirections, while preventing movement of table 204 in the Z direction.The movement of table 204 may be controlled by two manual actuators,wherein a first actuators 205 is configured to move table 204 in the Xdirection, while the second manual actuators 206 is configured to movetable 204 in the Y direction. Therefore, embodiments of the inventionessentially provide for movement of table 204 in three dimensions, i.e.,x, y, and z, via actuation of manual actuators 205, 206, and 211,respectively. Therefore, embodiments of the invention provide for atable 204 that may be precisely moved in a three-dimensional space withrespect to a fixed plate, i.e. plate 202, for the purpose of measuringand/or pressing optical components into optical housings or other areas.

FIG. 2 also illustrates another feature of the optical componentassembly apparatus 100. More particularly, FIG. 2 illustrates aplurality of air pressure regulators 208, which are generally in fluidcommunication with individual air bags 104. As such, when a force isexerted on an individual side of the leg portions of frame member 102, achange in the air pressure was in the corresponding airbags 104 will benoticed in a corresponding one of the pressure regulators 208. Inresponse thereto, the air pressure to be airbags 104 may be increasedand or decreased to maintain frame member 102 in a predeterminedorientation, i.e., to maintain frame member 102 in a verticalorientation, for example. Therefore, embodiments of the invention mayinclude a controller, i.e., a microprocessor type controller, forexample, which may be in electrical communication with air bagregulators 208, and therefore, operate to automatically maintain thepredetermined orientation of frame member 102. Additionally, anotherpressure regular 208 may be in fluid communication with pneumaticcylinder 209 for the purpose of maintaining slide 210 in essentially azero gravity type situation.

Optical measuring device 207 generally includes a camera 225 positionedon a lower portion thereof. An intermediate portion of optical measuringdevice 207 generally includes a magnification unit 226 that is inoptical communication with an intermediate assembly configured toprovide backlight to the entire optical measuring device 207. The upperportion of optical measuring device 207 may include a lens assembly 228configured to receive optical signals therein and transmit the opticalsignals through the entire optical measuring device 207 to the camera225. Optical measuring device 207 is generally mounted within press andmeasuring assembly 105, and more particularly, optical measuring device205 is generally mounted such that the lens assembly 228 is positionedimmediately below an aperture formed in movable plate 204. Therefore, inthis configuration, lens assembly 228 is configured to view an opticalsignal generated from an optical component mounted within a fixturepositioned on upper work plate 202.

FIG. 3 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention. Press assembly 300, which mayalso be termed a press tool, generally includes a substantially rigidbase member 301 that supports the remaining elements of press assembly300. A pair of upstanding support members 302 are attached to basemember 301 in a configuration that provides for a working space betweenthe two support members 302. The inner surfaces of upstanding supportmembers 302 include a vertical channel 310 formed therein, wherein therespective channels 310 formed into the support members 302 arepositioned opposite of each other. Additionally, a central portion ofsupport members 302 includes a recess 311 configured to support apivotally mounted arm 309. A pair of longitudinal apertures are alsoformed into support members 302, wherein the apertures are configured tosupport pivotal securing members 308 therein. Pivotal support members308 are slidably positioned within the apertures and are configured tobe actuated to secure a pivotal mount 305 to support members 302. Aworkpiece support press 303 is positioned between support members 302,and in particular, support press 303 is slidably positioned withinvertical channels 310. As such, support press 303 is configured to moveonly in the direction of channels 310, which is vertical in the presentexemplary embodiment. Press assembly 300 further includes a pivotallymounted press arm 309 pivotally mounted to support members 302 viashafts/pivotal mounts 305. Press arm 309 attaches to support press 303at a first end, mounts to support members 302 via pivot mount 305 in amiddle portion, and attaches to a screw member 306 at a second end. Inthis configuration screw member 306 may be actuated to pivotally movepress arm 309 such that support press 303 moves vertically withinchannels 310. Press assembly 300 further includes a component mount 307positioned below support press 303 such that a component may besupported on component mount 307 and pressed into a housing supportedwithin aperture 304.

FIG. 4 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention having a component therein. Theexemplary press assembly 400 includes components similar to the assembly300 shown in FIG. 3. In particular, press assembly 400 includes a base401, support members 402, press support 403, press arm 405, and screw406. Press assembly 400 also includes a component support 410 mounted atdistal ends to press support 403. Component support 410 is attached topress supports 403 such that component support 410 remains stationarywith respect to press support 403.

FIG. 5 illustrates a side perspective view of an exemplary cam operatedlaser press assembly fixture or press tool of the invention. The pressassembly 500 includes a base 501, an upstanding support 502, slidablymounted press support member 503, a pivotally mounted press arm 505, anda screw assembly 506. Additionally, a fixed component mount 510 isillustrated. In this embodiment, screw assembly 506 may be actuated todrive a second end of arm 505 upward as a result of pivotal movementabout a pivot point 509. The pivotal movement causes a first end (theend opposite second end that is attached to the press support member503) to move downward. In this manner an optical housing secured withincomponent mount 510 may have an optical component (optical source, lens,or other component) pressed therein by press support member 503 viaengagement of the component with a stationary fixture or component pressmounted to the base 501.

More particularly, in operation, the embodiments of the inventionillustrated in FIGS. 3, 4, and 5 generally operate in the same manner topress a laser into an optical housing. In particular, the press assemblyis generally configured to support an optical housing in a face downmanner, i.e., in a manner such that the output of the optical componentis directed toward the base plate 401, for example. In this manner thepower leads for the laser being pressed into the housing are generallyextending upward from the housing having the laser therein such that apower fixture may be attached to the power leads in order to power thelaser during the pressing operation. As such, the laser is generallyoperating, i.e., emitting an optical signal during the pressing process.However, as noted above, the efficiency and intensity of the opticalsignal is dependent upon the pressed position of the optical source orlaser. Therefore, it is critical that the optical source be pressed to aprecise depth within the optical housing such that the output isoptimized. This optimization is generally dependent upon the opticalsource being pressed to the optimal focal point within the opticalhousing. Further, the base member generally includes an aperturepositioned below the optical housing having the laser pressed therein,such that the optical output of the laser is directed through theaperture. Thus, when the screw assembly is actuated, the press arm movesdownward and presses the activated optical source into the housing whilethe optical signal generated by the optical component is transmitteddownward through the base of the fixture. This signal may then beobserved by the camera positioned there below.

FIG. 6 illustrates a side perspective view of an exemplary automated camoperated laser press assembly fixture or press tool of the invention.The automated press assembly 600 generally includes components similarto the previously discussed press assemblies, however, the adjustment ofthe x, y, and z position of the press and/or camera is accomplished viaan automated process, i.e., without manual adjustment. The pressassembly 600 generally includes a y-axis actuator 601, an x-axisactuator 602, and a z-axis actuator 603. Each of the respectiveactuators are in communication with a system controller configured tocontrol the operation of the actuators. The controller is generallyconfigured to receive input from the camera mounted on the press andmeasurement assembly and actuate each of the respective actuators inorder to obtain an optimal optical parameter. For example, the actuatorsmay be controlled to press a lens into an optical mount to an optimalfocal point via measurement of the output intensity and shape of theoptical output of the component. Similarly, the automated press assembly600 may be configured to press an optical source into an optical housingto an optimal depth via an automated process.

Generally, the automated process includes monitoring the optical outputof the component being assembled via a camera, such as camera 225illustrated in FIG. 2. The camera, or other device configured to measurean output parameter of an optical source, may be in communication with acontroller, such as a micro processor-type controller, for example. Thecontroller is generally configured to compare the output to a preferredor predetermined output, and then adjust the x, y, and/or z positionadjustments in order to adjust the output closer to the desired output.The process may continue until the output is within an acceptable range,which is generally optimal for the component. The analysis and/orcomparison process of the controller may be conducted in accordance witha software program stored in memory and executed on a processor.

FIG. 7 illustrates another fixture or press tool that may be implementedwith the press and measuring assembly of the invention. The pressfixture illustrated in FIG. 7 generally includes a substantially rigidbase 700. A slidably positioned assembly clamp 701 is positioned on anupper side of base member. Clamp 701 is generally configured to slideinto a position to secure an optical component to a workpiece support706 during the press or measurement operation. Additionally, a pair ofrelease latches 702 are generally positioned adjacent the support 706,wherein the release latches are configured to raise an optical componentsecured to the support once the pressing operation is completed. Thelower side of base 700 generally includes differential press screwassembly 703 that includes a screw actuator 705 and a lens press nut704. The differential press screw 703 threadebly engages base 700, andtherefore, may be actuated into base 700 via rotational actuation ofscrew actuator 705. In this configuration a lens or other opticalcomponent may be positioned on the lens nut 705 and pressed into anoptical housing secured on support 706.

FIG. 8 illustrates a sectional view of the differential press screwassembly illustrated in FIG. 7. The differential press screw assemblygenerally includes a hollow interior optical path 810 and an outer screwactuator 801 that has a first annular surface including a first threadedregion 804 formed thereon. Screw actuator 801 further includes a secondannular region having a second threaded region 803 formed thereon. Screwactuator is assembled into the fixture by threadebly engaging a firstinner threaded surface with the first threaded region 804. A distalextending end of the actuator 801, i.e., the end proximate the secondthreaded region, extends into an inner cavity of the fixture, where alens press nut 805 is slidably positioned. Lens press nut 805 includesan outer surface that slidably engages the inner surface of the fixture.Additionally, an inner surface of nut 805 includes a threaded bore 808that is configured to threadebly engage the second threaded region 803of actuator 801. In this configuration, screw actuator may be rotated tocause the lens press nut 805 to extend into an optical component space806. Thus, in operation, a lens to be pressed into an optical componentmay be positioned either on nut 805 or within an optical component thatis positioned or secured within component space 806. With the componentsecured, the screw actuator may be rotated to press the lens into therespective optical housing to a specific depth. The depth may be set bythe mechanical setup of the differential screw, or alternatively, thedepth may be determined through an automated process. For example,embodiments of the invention may utilize the camera assembly 225illustrated in FIG. 2 to analyze the output of the optical componenthaving the lens pressed therein. The analysis process, which will befurther discussed herein, generally includes pressing the lens into thecomponent while simultaneously viewing the optical output of thecomponent. This output may be compared to a desired optical output todetermine if the lens has been pressed into the component to the properdepth, i.e., to the focal point.

In operation, embodiments of the invention provide a method forassembling and/or measuring optical properties of an optical component.The assembly and measurement process may be accomplished real time,i.e., the optical component may be active during the assembly and/ormeasurement processes. For example, assuming that the component beingassembled and/or measured is an optical component having an opticalsource therein, then the optical source may be assembled within anoptical housing with the power to the optical source being on during theassembly process. The assembly process generally includes pressingeither an optical source, i.e., a laser, into a component, oralternatively, pressing an optical component, i.e., a lens, into acomponent already having a source via a press tool (various press toolsand configurations may be used without departing from the scope of theinvention). In this manner, the optical output of the component may bemeasured during the assembly process. Further, the optical output may beused as a control parameter for the assembly process, as the intensity,shape, contrast, and other parameters of the optical output may bemeasured and compared to a desired value in order to determine, forexample, if the optical source is optimally positioned within theoptical housing.

More particularly, FIG. 8 a illustrates a flow diagram of an exemplarymethod of the invention. The methodology illustrated in FIG. 8 a isdirected to an embodiment of the invention wherein an optical source,i.e., a laser for example, is pressed into an optical housing. However,it is to be understood that the present invention is not intended to belimited to this embodiment, as the methodology is generally applicableto assembling various optical components that emit an optical signal.For example, the methodology may be utilized to press a lens into anoptical component while monitoring the output of the component todetermine when the lens is pressed to an optimal point, such as thefocal point, for example. Further, the inventors contemplate thatvarious other optical components may be assembled using the basicmethodology of the invention.

The exemplary method illustrated in FIG. 8 a is generally directed to anembodiment wherein a laser is being pressed into an optical housing.Therefore, the embodiment illustrated in FIG. 8 a is generallyconfigured to press the laser to an optimal distance within the opticalhousing such that the optical output is optimized. The process ofpressing the laser to the desired distance is accomplished by pressingthe laser while observing the output of the component, as the laser ispowered on during the pressing process. The laser is then pressed untilthe output is observed as being optimal, which corresponds to theoptimal press depth. The method generally begins at step 801 wherein alaser is pre-mounted into an optical housing. At this stage the laser isgenerally mounted within the housing, but is mounted such that the lasermay be longitudinally actuated within the housing in order to adjust theposition of the laser relative to other components within the housing.Once the optical sources are mounted within the optical housing, theentire component may be mounted within a palette or fixture configuredto secure the component for the press and measurement operations. Forexample, the optical component may be mounted within a fixture, such asthe exemplary fixtures illustrated in FIGS. 3, 4, 5, 7, or 8. Once theoptical component is secured in the appropriate fixture, the fixture maybe secured to an apparatus configured to press the optical source withinthe optical housing, as well as measure the optical output of thecomponent during the pressing process.

However, prior to initiating any measurement processes, embodiments ofthe invention generally provide for initializing the apparatus forconducting the pressing and measurement processes. For example, steps803 and 804 of FIG. 8 a illustrates initialization steps that aregenerally conducted prior to beginning a press and measurement process,or alternatively, prior to beginning a press and measurement process fora plurality of components, i.e., a batch. The initialization steps 803generally corresponds to the processes associated with centering theworking surface upon which the above-mentioned fixtures will be mountedwith respect to a machine reference center. Further, step 803 may alsoinclude initializing the station to a reference Z plane, i.e.,determining the Z position of the working surface with respect to theother components of the system, or alternatively, with respect to areference Z position. Step 804 further illustrates initializationprocesses, and in particular, illustrates and initialization processthat includes making initialization measurements with a backlight laserin a power off position. Initialization process of the present inventionmay further include initializing control devices and for systems, suchas, for example, software routines, device controllers, power supplies,cameras, lighting equipment, pressure regulators, and other apparatusesor devices that may be used in conjunction with the optical componentassembly and measuring apparatus of the invention. Therefore, theinitialization process is generally configured to initialize the x, y,and z position of the workpiece support relative to the opticalmeasuring equipment. Further, the initialization processes areconfigured to align the respective axes of the apparatus with eachother, i.e., aligning the x and y axes to be exactly perpendicular toeach other, while also positioning the Z axis perpendicular to the x andy axes.

Once the initialization process is complete, and the palette or fixtureis mounted on the working surface of the press and measurement apparatusof the invention, that the method may continue to step 805, wherein theapparatus measures the facet location of the component without the powerbeing applied to the optical source. The measured facet location maythen be recorded by an automated control system in communication withthe apparatus, such as, for example, a microprocessor based controllerconfigured to control the operation of various components of theinvention. In the illustrated embodiment, the microprocessor basedcontroller may include a personal computer configured to receive inputfrom the measuring device, where the input may represent datacorresponding to the measured facet location, and place the input into astorage medium, such as a hard drive or other commonly used computerstorage medium. Thereafter, this input may be accessible to variousother control systems, such that the measured facet location of theparticular component may be used to conduct various other assembly ormodification processes on the particular component in conjunction withthe measurements taken within the press and measuring apparatus of theattention. Once the power off facet location has been measured at step805, the exemplary method of the invention continues to step 806, wherethe optical source of the component being pressed and measured ispowered on. Once the optical source of the component is powered on, themethod continues to step 807. At step 807 an initial measurement istaken of the optical output of the component with the optical sourcepowered on. This initial measurement is generally a rough measurementconfigured to determine if the component is within tolerances. Forexample, if the optical output of the component is extremely misaligned,it may not be possible to correct for the misalignment, and therefore,the component may be discarded. Therefore, embodiments of the inventionprovide an apparatus that method configured to eliminate parts that arenot within an initial tolerance range immediately without expending timeand resources on the assembly and measurement process. As such, thatmethod apparatus of the invention provides an efficient and accurate wayof eliminating bad order parts prior to expending resources onprocessing the invention order parts.

Once the optical device is powered up in step 806, a measurement device,such as a camera or other device configured to receive and determine theposition of the optical signal output from the component beingassembled, may be used to determine both the x and y position of theoptical output relative to a reference point, as well as the thresholdpower of the optical output, as illustrated steps 808 and 809. Themeasurements taken at steps 808 and 809 may be committed to a databasethat is accessible to various systems, as illustrated in its steps 810and 811. Once the power on x and y coordinates are determined and storedin the database, the method continues to step 812 wherein the laserfocus is determined. In this step, the laser focus is generallydetermined through careful selection of the z position of the camerarelative to the output of the optical device. Furthermore, both the xand y positions may be varied during the focus determination, such thatthe field of view of the camera is consistently able to capture theentire optical signal emitted by the optical component. Thus, in orderto determine the laser focus the present invention, the apparatusessentially scans in the z direction looking for a predetermined ordesired contrast that generally corresponds to laser focus, whilemaintaining the contrast invention within the field of view of thecamera via adjustment of the x and y position of the camera or thefixture having the component secured therein. The process of adjustingthe x, y, and z position is represented by step 813.

The data obtained in step 813 is then committed to a database for futureuse, as illustrated in step 814. The method further includes calculatingthe offset of the optical signal emitted from the optical componentposition within the measuring apparatus, as illustrated in step 815.More particularly, the process of calculating the offsets illustrated instep 815 may generally include determining the x coordinate, ycoordinate, and z coordinate with respect to a reference point, plane,or axis of the system, wherein the x, y, and z coordinates generallycorresponds to the position of the optical signal at the location or theoptical signal is in focus, i.e., the focal point. Additionally, step815 includes the process of calculating a pointing angle, wherein thepointing angle generally corresponds to the angle between a horizontalaxis extending from the optical source to a separate axis extending fromthe emission point of the optical source to the point on the referenceplane in the determined z position. Thus, the pointing angle generallycorresponds to the angle between the optimal signal trajectory axis,i.e., the axis upon which the optical signal would travel away from theoptical component if there were zero offset present in the component,and the axis upon which the optical signal actually travels away fromthe optical component. Since these two axes are different, the pointingangle represents the angle between the respective axes.

Once the respective components of the offset are calculated, thecomponents are generally committed to one or more databases, asillustrated in step 816. In the exemplary embodiment illustrated in FIG.8 a, individual databases are set up to receive the individual plane orcomponents, as well as a separate database configured to receive thepointing angle for each component measured in the exemplary apparatus ofthe invention. With the optical offset measured and recorded, the methodof the invention generally continues to step 817, where the opticalcomponent is removed from the fixture or palette of the invention.Thereafter, the optical component may be moved to a separate apparatusconfigured to compensate for the optical offset inherently presentwithin the optical component, wherein the optical offset has beenmeasured and stored in the above noted databases, as illustrated in step818.

Once the optical component is moved to a second machine configured tomechanically adjust the optical offset of the component, as stated instep 818, the second machine may access the previously stored data,i.e., the data obtained at step 816, 810, 811, and 814, in order todetermine what physical modifications may be made to the component tocorrect for the optical offset. For example, the information obtained instep 815 and stored in step 816 may be used to determine what portionsof the outer diameter of the optical housing/optical component may bemilled in order to counteract for the optical offset of the component.Put simply, the offset information may be used to determine whatportions of the outer mounting surface of the optical component may bemilled or shaved away in order to physically adjust the optical axis ofthe component such that the optical output is aligned with the center ofthe component, i.e., such that the optical offset of the output of thecomponent is removed or at least counteracted via the physicaladjustment of the mounting surfaces of the component, which isillustrated in step 819 and 820. Once the outer portion of the opticalcomponent is machined to adjust for the optical offset measured in theabove noted process, the method may continue to press the laser into thehousing at step 821, mount the optical component on the camera stationat step 822, and then mechanically adjust for the optical housing, i.e.,a bend component, at step 824, in order to finally align the opticaloutput of the optical component. Once the final alignment has been made,the information corresponding to measurements of the optical componentmay be committed to a database at step 825. The information contained inthe database may then be accessed by other component assembly processes,sales processes, test processes, and or any other processes associatedwith optical components such that the exact parameters of the component,i.e., the outer dimensions and the characteristics of the opticaloutput, may be taken into account in subsequent processes.

FIG. 9 illustrates a graphical view of the optical offset measurementprocess 900. The graphical illustration of measurement process 900 isbest illustrated with respect to three reference axes, i.e., x axis 909,y axis 910, and z axis or machine 0 axis 901. The optical signalemitting end of the optical component being measured is generallyrepresented by 902. Therefore, if the optical component to admitting theoptical signal is perfectly aligned, then the optical signal will betransmitted therefrom and intersect the x-y plane at point 911, whereinpoint 911 is positioned directly below point 902. By away of example, ifthe point of optical emission corresponds with the machine 0 axis andthe optical component is perfectly aligned, then the point at which theoptical signal intersects the x-y plane will correspond with theintersection of axis 901, axis 910, and axis 909. When the optical point911 does not correspond with the machine zero point, then the offset ofpoint 911 may be measured, and generally is measured in terms of the xcomponent of the machine offset 904 and the y component of the machineoffset 906. However, regardless of the initial position of point 902,the measuring apparatus and method of the invention may calculate theoptical offset of the component. More particularly, once the opticalcomponent to be measured is positioned within the apparatus of theinvention, the optical component may be powered all on such that the 10optical signal is admitted therefrom. The optical signal, which isgenerally represented by arrow 912 in FIG. 9, propagates towards the x-yplane and intersects the plane at point 903. Since point 903 does notcorrespond with point 911, it is apparent that the optical component hasan offset. Therefore, embodiments of the invention are configured tomeasure the offset between point 903 and point 911, and furthermore,correct for the optical offset between the respective points.

Once point 903 is determined, the method of the present invention maycalculate the x-component 905 of the optical offset, the y-component ofthe optical offset 906, the pointing angle 908, and the z-axiscorrection for the optical offset/focal point. In particular,trigonometric calculations may be used to determine each of the abovenoted in parameters from the measured position of point 903 in themeasurement plane. However, the z-direction offset and the pointingangle are generally not measured parameters, as they need to becalculated from the measured parameters, i.e., the x and y components ofthe measured offset. Further, although the pointing angle is animportant to the method of the invention, the calculation of the z-axisoffset correction is critical to the future operation of the component.More particularly, as described in the methodology above, themeasurement plane generally corresponds to the focal point of thecomponent. However, the focal point of the component as measuredcorresponds to the focal point to at the offset, and therefore, once theoffset is corrected, the focal point measured for the component with theoffset when the longer be valid for the component with the offsetcorrected. By way of explanation, the path of optical signal 912generally corresponds to the hypothenuse of a triangle consisting of afirst side (the z direction side) and a second side (the reference planeside). Therefore, when the pointing angle is minimized, i.e., when theoffset is corrected, then the hypothenuse generally corresponds with thefirst side of the previously mentioned triangle. Since the hypothenuseis always longer than either of the remaining sides of a triangle, it isapparent that the measured focal point of the optical component with theoptical offset the will be shorter then the two focal point of thecomponent with the optical offset corrected, as when the hypothenuse isswung toward the first side, it will be longer than the first side.Thus, it is important to calculate and record the z-offset correction,as this number will directly change the previously measured focal pointdistance of the component.

In another embodiment of the invention the press and measurementapparatus of the invention may be used to press an optical componentinto an optical housing proximate an optical source. More particularly,the apparatus of the invention may be used to press an optical lens intoan optical housing having an optical source therein. In this type ofpressing operation the lens may be pressed into the optical housingtoward an optical source, such as a laser, for example, while the outputof the component is observed or measured by the apparatus of theinvention. Thus, the pressing operation, i.e., the depth to which thelens is pressed into the housing, may be controlled in accordance withthe optical output of the component as the lens is pressed therein. Moreparticularly, the optical output may be observed in order to press thelens to the optimal focal point of the device via observance of theoptical output. The observance process may include observing and/ormeasuring the intensity, shape, configuration, contrast, and otherparameters of the output and comparing the observed parameters toparameters corresponding to a component that is optimized. Thecomparison process may then be used to control the press operation toinsure that the lens is pressed to the optimal depth, which is generallythe focal point.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow

1. A pallet for pressing a lens into an optical housing, comprising: asubstantially rigid base member having a press aperture formed therein;an optical housing support positioned above the press aperture; at leastone pivotally mounted optical housing disengagement member; and adifferential press screw assembly positioned on an opposing surface ofthe base member from the optical housing support.
 2. The pallet of claim1, wherein the optical housing support comprises a slidably positionedassembly clamp.
 3. The pallet of claim 1, wherein the differential pressscrew comprises: an outer press assembly having a first outer threadedsurface and a first inner threaded surface; and an inner press assemblyhaving a second outer threaded surface configured to threadebly engagethe first inner threaded surface, the inner press assembly having anextending lens press nut.
 4. The pallet of claim 3, wherein the innerpress assembly in configured to actuate toward the press aperture uponrotation of the outer press assembly and engagement of the first outerthreaded surface with a threaded surface of the base member.
 5. Thepallet of claim 3, further comprising a screw actuator in communicationwith the outer press assembly.
 6. The pallet of claim 1, wherein the atleast one pivotally mounted disengagement member comprises twoopposingly positioned release latches configured to pivot upward todisengage the optical housing from the optical housing support after thelens is pressed therein.
 7. The pallet of claim 1, wherein thedifferential press screw assembly further comprises a longitudinal boreformed therethrough, the longitudinal bore being configured transmit anoptical signal from the optical housing to a measuring apparatuspositioned below the differential press screw assembly.
 8. An assemblyfor pressing a lens into an optical housing, comprising: a base memberhaving an aperture formed therethrough; an assembly clamp positioned onan upper surface of the base member above the aperture, the assemblyclamp being configured to support the optical housing above the apertureduring the pressing operation; and a differential press screw assemblypositioned over the aperture and on a second surface of the base member,the differential press screw being configured to press a lens upwardthrough the aperture into the optical housing.
 9. The assembly of claim8, comprising a pair of pivotally mounted release latches positionedadjacent the assembly clamp, the latches being configured to disengagethe optical housing from the assembly clamp.
 10. The assembly of claim9, wherein the differential press screw assembly comprises: a firstscrew press having a first outer threaded surface and a first innerthreaded surface, the first outer threaded surface being configured tothreadebly engage a threaded surface of the base member; and a secondscrew press having a second outer threaded surface configured tothreadebly engage the first inner threaded surface.
 11. The assembly ofclaim 10, further comprising a lens press nut attached to the secondscrew press.
 12. The assembly of claim 11, wherein the lens press nut isconfigured to support a lens thereon and extend through the aperture andinto the optical housing to press the lens into the housing.
 13. Theassembly of claim 9, further comprising a screw actuator attached to thefirst screw press.
 14. The assembly of claim 13, wherein the screwactuator comprises a motor in communication with a controller, thecontroller being configured actuate the motor in response tomeasurements taken from the optical component while the lens is beingpressed into the optical housing.
 15. The assembly of claim 10, whereinthe first screw press and the second screw press comprise a longitudinaloptical signal transmission bore formed therethrough.
 16. A fixture forassembling an optical component, comprising: a substantially rigid basemember having an upper surface, a lower surface, and a base apertureconnecting the upper and lower surfaces; a component mounting platepositioned on the upper surface and having an aperture formed thereinthat is positioned to correspond with the base aperture; at least onepivotally mounted component disengagement member positioned on the uppersurface and being configured to disengage a component from the mountingplate; a component securing member slidably positioned on the uppersurface and being configured to secure a component in the aperture ofthe mounting plate; and a differential press screw positioned on thelower surface and extending through the aperture.
 17. The fixture ofclaim 16, wherein the at least one pivotally mounted componentdisengagement member comprises two opposingly positioned pivotal latcheshaving distal extending members that are configured to disengage anoptical component from the aperture of the mounting plate.
 18. Thefixture of claim 16, wherein the component securing member comprises aslidable member having two extending fingers that are configured tosecure the optical component in the aperture of the mounting plate whenthe fingers are positioned above the mounting plate aperture.
 19. Thefixture of claim 16, wherein the differential press screw comprises: anouter screw press having a first outer threaded surface and a firstinner threaded surface; and an inner screw press having a second outerthreaded surface configured to threadably engage the first innerthreaded surface, wherein the first outer threaded surface threadeblyengages the base member while the first inner surface threadably engagesthe second outer threaded surface to longitudinally actuate the innerscrew press.
 20. The fixture of claim 19, further comprising a lenspress nut positioned in communication with the inner screw press. 21.The fixture of claim 20, further comprising a screw actuator positionedin communication with the outer screw press.
 22. The fixture of claim21, wherein actuation of the screw actuator is configured tolongitudinally extend the lens press nut toward the optical componentand press a lens positioned thereon into the optical component.